Owner s Manual & Service Records

Transcription

1 Owner s Manua & Service Records

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3 Owner s Record A correspondence reating to service probems may be addressed to: SERVICE DEPARTMENT, BAJAJ USA 525 ECCLES AVENUE SOUTH SAN FRANCISCO, CA Notice: The description and iustration in this booket are not to be taken as binding on the manufacturers. The essentia features of the type described and iustrations herein remaining unatered, Bajaj Auto Limited reserves the right to carry out at any moment, without being obiged to bring this booket up-to-date, modifications on the vehice, parts or accessories as may be convenient and necessary. Name : Vin # : Chassis # : Engine # : Date Purchased : Deaer :

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5 Deivery Certificate Customer s Name : To REMOVE - TEAR HERE Address : Date Purchased : Deaer : To be removed & retained by deaer.

6 Deivery Certificate Vin # : Chassis # : Engine # : The above vehice was inspected/test driven by me/my representative at the time of taking deivery and it was found to be acceptabe and free from any operationa or visua defects. A copy of the owner s manua containing service requirements, five service record pages, and a warranty statement was given to me aong with the vehice. I understand that my warranty caims, if any, wi be considered by the manufacturers ony in accordance with the scope & imits of the warranty as aid down in the Warranty Statement. Pace : Date : Customer s Signature To be removed & retained by deaer.

7 Pre Deivery Inspection Check and correct tire pressure incuding that of Spare Whee. Check and tighten nuts for front/rear shock absorber bots, engine foundation bots, hande bar ock bot and front/rear whee nuts. Check transmission and engine oi eve and top up if necessary. Check for smooth operation of acceerator and choke operation. Check and adjust Steering coumn for oose/tight. Initia charging of battery, Insta, connect and appy petroeum jey on terminas. Check and adjust engine iding. Check steering/ignition ock, uggage box ock, seat ock, and too box ock for proper operation. Check a ights, horn, switch, speedometer and fue gauge operations for satisfactory working condition. Check for smooth operation of fue cock ever. Check front/rear brakes for effective working condition. Test drive the vehice. Repair any other defects seen or observed during test drive. Cean the vehice before deivery.

8 Important Precautions The foowing precautions must be observed if your vehice is fit with a cataytic converter. If you are unsure whether your scooter has a cataytic converter or not, check with your deaer. The cataytic converter, which is instaed inside the siencer, reduces the exhaust emissions and is required in some states. Caution: 1. Never operate your scooter with eaded gasoine. Even a sma amount of norma eaded gasoine wi damage the catayst and make the cataytic converter competey ineffective. 2. Never tamper with the cataytic converter, which is instaed inside the siencer assemby. 3. Never turn off the engine when the scooter is in motion. Likewise, never try to start your scooter by pushing it, towing it, or coasting it down a hi. Faiure to observe this precaution wi damage the cataytic converter, and can ead to a serious over temperature event, or even a fire, with subsequent serious injury to you and serious damage to your scooter. 4. If the engine misfires or appears to have any oss of performance, immediatey take your scooter to your oca Bajaj Deaer.

9 Heo! Dear Customer, We wish to congratuate you for choosing The Bajaj Chetak 4 Stroke, coming from Bajaj Auto the word s argest manufacturer of scooters. Chetak 4 Stroke wi give you vaue for your money, for years! We are sure that you wi be proud of its performance. Pease read this Owner s Manua before riding to famiiarize yoursef with the mechanism and contros of the vehice. To ensure a ong, troube free ife of your vehice, give it proper care and maintenance as described in this manua. It is important to reguary inspect and maintain your scooter for safe and optimum performance. Reguar inspection and service is required to maintain your warranty. The warranty period for this scooter is 12 months or 6,000 mies, whichever comes first. See the service record pages in this booket for the required service and inspection intervas. Entrust the maintenance and repairs to the authorized Bajaj Deaers, who are we equipped with necessary faciities and are speciay trained on BAJAJ CHETAK 4 STROKE. In case you need detaied information about your vehice, the Service Station Manua is avaiabe from authorized Bajaj Deaers. In the rare event of a probem with your vehice, pease write to Bajaj USA, giving detais ike engine number, chassis number, date of purchase etc.

10 Tabe of Contents Description Identification Data 1 Technica Specifications 2 Location of Contros and Components 3 Genera Information 10 Running In 15 Periodic Maintenance Chart 17 Lubrication Chart 18 Changing Tires 19 Safety Recommendation 22 Service Records

11 Identification Data and Vehice Identification Number # AD72233 # Engine Number Chassis Number VIN Number There are three unique numbers assigned to your scooter. The engine and chassis seria numbers are used by the factory to identify the exact mode. Pease cite both of these numbers whenever you are ordering repacement parts. The vehice identification number is used to register your vehice with the Department of Motor Vehices in your state. It is a crime in a states to ater the vehice identification number. Aso, the ateration of any of these numbers wi immediatey void your warranty. 1

12 Technica Specifications Engine : 4 stroke, singe cyinder, forced air cooed, spark ignition 3 Engine Dispacement : cm Max. Net Power : 9.00 HP at 6000 r/min of engine Ignition System : Eectronic ignition (C.D.I.) Spark Pug : Champion : PL 7 YC (To be used with resistor spark pug cap) Lubrication : Wet sump forced ubrication Transmission : 4 speed gear box Front & Rear Brakes : Mechanica expanding shoe type Fue Tank Capacity : 1.32 Ga. (5.00 itres) Eectrica System : 12V D.C. : Head amp : 35/35W Tai/Stop amp : 5/21W Side indicator amp : 10W Horn : 12V D.C. Curb Weight : 253 bs/115 kg Max Speed : 55 MPH/90km/h with singe rider Note: The above information is subject to change. 2

13 ENGINE STOP Location Of Contros / Speedometer / Rear View Mirrors Hande Bar R 10 0 Speedometer MIPH 20 F N MILES Cutch Lever 2. Mirror LH 3. Speedometer 4. Mirror RH 5. Luggage box ock 6. Fr. Brake Lever 7. RH Switch 8. Steering Lock / Ignition Switch 9. LH Switch 1. Hi-Beam Indicator 2. Turn Signa Indicator 3. Speedometer 4. Odometer 5. Fue Gauge 6. Neutra Indicator 10. Acceerator 11. Gear Shifter 3

14 The Steering Lock / Ignition Switch is ocated on the right hand side beow the hande bar. It has three positions. Steering Lock / Ignition Switch Key Position LOCK OFF ON To Lock the Steering Turn the hande bar to the eft. (Steering wi be ocked ony when hande bar is in eft position.) With the key in OFF position and turn it to the ock position. Take out the key. Function Steering ocked Ignition OFF Steering unock Ignition OFF Ignition ON Key Remova Key can be removed Key can not be removed Steering Lock 4

15 Fue Tank RES OFF ON Fue Cock Position Fue Tank It has capacity of 1.32 ga. Location of fue tank is as shown in the figure. Fue Gauge The fue eve gauge is provided in the speedometer consoe to indicate the fue quantity in the fue tank. Fue eve is indicated as foows: E mark indicates approx. Empty. Mid mark indicates approx ga. F mark indicates approx ga. Fue Cock It has the foowing three positions On : When fue eve is above 0.26 ga. Res : When fue eve drops beow 0.26 ga. Off : Fue suppy is cut off. Warning: Never mix oi in the gasoine. To do so can ead to engine faiure and subsequent accident with potentiay serious injury or even death. Use ony uneaded gasoine of research octane number 87 or higher. There is serious danger of fire if gasoine is eaking from any portion of your vehice. Never ride your vehice if you sme gasoine. Have your vehice repaired immediatey by your authorized Bajaj deaer. Faiure to heed this warning can ead to a serious fire, with subsequent serious injury or even death. 5

16 RES OFF ON Off A On B A A Choke Lever It is ocated near the fue cock ever. Choke is required especiay for cod starting. The On and Off positions of choke ever are as shown in figure. A : Choke OFF B : Choke ON A : Seat Lock Seat Lock : It is ocated on eft hand side of the seat. The ock ensures the security of the fue tank. Turn the key cockwise to unock seat. For ocking, genty press the seat from top. A : Too Box Lock Too Box Lock : It is ocated as shown in the figure A. Key can be removed after ocking as we as unocking the Too box. 6

17 OFF B ENGINE STOP Right Hand Switch Left Hand Switch RUN A B A C Right Hand Switch A Starter switch : Press the button to start the engine. B Suppementary engine stop switch : Move to the Run position before starting engine. Move to the Off position to stop engine. Left Hand Switch This scooter is equipped with ights that iuminate whenever the ignition is turned on. A Turn signa switch : Move the knob eft or right to activate turn signa. Move back the knob to center position to OFF turn signa. B Horn Switch : Press to activate horn. C Headight High/Low beam switch. Press the togge upward for high beam, press the togge downward for ow beam. 7

18 A : Spare Whee B :Whee Cover A B A : Took Kit B : Jack 8 Spare Whee : Spare whee is ocated behind seat on bracket. For removing the whee : Remove the whee cap. Remove the spare whee mounting bots. (Ref. Fig. A) Whee Cover The whee covers are fitted to a whees. B: Whee Cover Too Kit : Too kit is strapped (by rubber strap) inside the Luggage box. Unock the Luggage box, remove strap and take out too kit. Refer Fig. A Jack : Jack is strapped (by rubber strap) inside the Luggage box. Unock the Luggage box, remove strap and take out jack. Refer Fig. B Warning: Proper tire pressure is very important to the handing of your scooter, and to your safety. Never ride your scooter with tires either over or under-infated. See the specifications tabe on page 12. Faiure to observe this warning can ead to instabiities in handing and an upset with subsequent serious accident, injury, or even death. Note: Rear brake iner wear can be inspected through window on rear brake drum by unscrewing the pug on it. Front brake iner wear can be inspected by ooking at the wear indicator on front brake actuating ever.

19 Battery Battery (12V - 9Ah) Battery is ocated at LH side inside the Cow. Check & ensure that the eectroyte eve is between the upper and ower eve ines in each ce. If the eectroyte eve is beow the ower eve in any ce, fi to upper eve with distied water ony. Inspect the terminas. Cean if corroded. Tighten the battery camps, then appy a itte petroeum jey. Ordinary tap water is not a substitute for distied water and wi shorten the ife of the battery. Oi Fiter Ceaning Oi fiter is situated inside the bot as shown in the figure. Oi fiter shoud be ceaned in accordance with ubrication chart by an Authorized Bajaj Deaer. Location of Oi Fiter and Drain Bot Warning : Faiure to ensure that your engine has the proper amount of the appropriate grade oi can ead to an engine seizure, with subsequent upset, serious injury, or even death. Aways ensure that your scooter has the proper amount and type of oi. 9

20 B C D Engine Oi A Genera Information A : Oi Fier Location B : Oi Leve Indicator C : Upper Leve D : Lower Leve Engine Oi: Check engine oi eve daiy. For proper functioning of cyinder bock/piston, crankshaft, tappets, cutch and transmission, the oi shoud be maintained at an appropriate eve. Pace the vehice on center stand, on a eve ground. Cean the surface area around the oi fier opening. Unscrew the dipstick from oi fier opening hoe and wipe it dry. Put the dip stick, on oi fier opening, take out the dip stick and observe the oi eve o n i t. There are two marks engraved on it. If the eve is beow the ower eve mark, remove the cap (A) & top up with the appropriate quantity of recommende d oi up to upper eve mark If the oi eve is too high i.e. Above the upper eve mark, drain some oi from drain hoe. Fit back the dipstick and tighten it securey. Ensure that there is no oi eakage. Recommended oi: In summer : 15W50 API SG + JASO MA or Superior In winter : 5W30 API SG + JASO MA or Superior Oi capacity : 1 Quart 10 A : Cap

21 Lubrication of the antidive front suspension A grease nippe is provided on Brake pane at ocation A (Ref. fig.) for ubrication of Brass bushes fitted inside Front brake pane assy. These Bushes are recommended to be greased after every 2000 mies. To ubricate Bush inner fitted inside Antidive ink assy at ocation B (Ref. fig.), you wi have to dismante and remove the Bush inner and then ubricate with Grease. The Bush inner are recommended to be greased after every 3000 mies. B A ANTIDIVE FRONT SUSPENTION Location Operation Recommended Interva A Lubricate through the Every grease nippe mies B Dismante, Remove Every Bush inner and then 3000 mies ubricate with grease. 11

22 Spark Pug Using compressed air, bow any oose dirt away from around the spark pug. Remove the spark pug using the specia spark pug wrench, cean the spark pug using a wire brush, or a proprietary spark pug ceaner. Adjust the gap if incorrect by bending the outer eectrode carefuy. Caution Never try to bend the center eectrode of the spark pug. This wi surey destroy your spark pug. Spark Pug Gap 0.6 to 0.7mm Spark Pug Champion PL 7 YC (To be used with a resistance spark pug cap) Tire Pressure Aways maintain the tire pressure as indicated in the tabe beow. Warning Faiure to maintain proper tire pressure can ead to instabiities in handing with subsequent upset, serious injury, or even death. Tire Size (A three tires) Front Rear Soo With passenger 18 psi / (123 kpa) 25 psi / (175 kpa) 36 psi / (245 kpa) 12

23 Starting Procedure (Kick Start) Ensure the transmission is in neutra. (Neutra amp in speedometer consoe shoud be iuminated) Ensure the Steering/Ignition ock is in the ON position. Ensure the Engine stop switch is in the RUN position. How to operate the kick starter : Move the kick-starter sowy. Make sure that the ratchet is engaged, then depress smarty. A) Norma Starting: Do not open throtte whie starting. If the engine fais to start, sighty open the throtte (not more than ¼ turn) before depressing the kick-start ever. B) Cod Starting: Use the Choke ony for cod weather starting. Pu the choke ever and depress the kickstarter ever. Do not open the throtte whie using the choke. Reease the choke ever to the OFF position once the engine has warmed up. Never rev up the engine to higher RPMs immediatey after starting or in neutra gear. If the engine is reved to higher RPMs immediatey after starting it may ead to severe engine damage as ubricating oi take some time to reach a the components. Starting Procedure (Eectric Start) Ensure the transmission is in neutra. (Neutra amp in speedometer consoe shoud be iuminated) Ensure the Steering/Ignition ock is in the ON position. Ensure the Engine stop switch is in the RUN position. Press the starter button to start the engine. Reease the starter button as soon as the engine starts. When the engine is cod, pace the choke ever ON, press the starter button with the throtte competey cosed. When the engine has warmed up reease the choke ever to the OFF position. 13

24 Moving from Stand Sti Position Pu the cutch ever to its fu trave and twist the shift ever tube upwards in one smooth motion to put the st vehice in 1 gear. Reease cutch graduay and simutaneousy, open the throtte graduay to move away from stand sti position. Do not run the vehice with the cutch partiay engaged. Do not sip the cutch to overtake or to cimb on a gradient. This wi damage the cutch. th rd Downshifting of gears i.e. Shifting from 4 to 3 to nd st 2 to 1 gear: Reduce the speed of the vehice. Pu the cutch ever competey and twist the gear ever upwards and reease the cutch ever graduay and increase throtte. For further ease of gear shifting sighty open the throtte momentariy whie puing the cutch ever and then twist the gear ever upwards. Do not keep the cutch ever depressed in neutra whie waiting at the traffic signas. This wi resut in Difficut gear shifting as the gear box is constant mesh type which requires rotation of gears for ease of engagement. Warning: Do not tit the vehice toward the LH bonnet side. Engine oi may fow out of through the crankcase breather tube, to air ceaner, owering the oi eve in the crankcase. Aso, shoud the vehice be aowed to fa accidentay on its eft side, ensure that the oi eve is correct after picking the scooter up and pacing it on the stand. Faiure to observe this warning coud ead to engine seizure with subsequent upset, serious injury, or even death. Battery eectroyte may aso eak out from the ces, if the vehice happened to fa on its eft side. Eectroyte being acid, can damage painting and rubber components. Spied acid around the battery area may be ceaned with water and baking soda to neutraize the acid. 14

25 Running In Running In First 500 mies is designated as a running in period. The maximum vehice speed recommended during running in: Distance in mies Max. vehice speed in gears (mph) 1st 2nd 3rd 4th Never exceed the specified running in speed. Do not over-rev the engine. Do not start moving or race the engine immediatey after starting. Run the engine for a minute at ide speed to give the oi a chance to work up into the engine. Never et the engine ug, that is, run at sow RPMs with wide-open throtte during the running-in period. Warning: You must run-in your vehice according to this running-in schedue if your scooter is to achieve its maximum ife and most reiabe service. Further, immediatey running the engine hard coud ead to an engine seizure with subsequent upset, serious injury, or even death. 15

26 Safety and Maintenance Tips Vehice Condition: Warning: There is a serious danger of fire if gasoine is eaking from any portion of your vehice. Never ride your vehice if you sme gasoine. Have your vehice repaired immediatey by your authorized Bajaj Deaer. Faiure to heed this warning can ead to a serious fire, with subsequent serious injury or even death. Check a fue ines and connections whenever your vehice smes of gasoine. Never fi with gasoine up to the fier cap. Aways maintain the recommended tire pressure and check it every week. Ensure that the brakes are not dragging/binding. For keeping the engine heathy: - Inspect and cean the spark pug, adjust the gap as recommended. - Use ony the recommended grade and quantity of engine oi. - Service the carburetor and adjust iding speed as recommended. - If there is a power oss, then contact an authorized Bajaj Deaer and get the vehice propery tuned. Good Riding Habits Ride smoothy and steadiy. Avoid harsh braking. For better fue economy, shift gears as given beow: st nd Change 1 to 2 gear at 6 mph nd rd Change 2 to 3 gear at 12 mph rd th Change 3 to 4 gear at 18 mph th Drive at 18 to 30 mph in 4 gear. Do not et your scooter ide for more than a minute. Turn off the ignition instead of permitting extended iding. 16

27 Indicates operation to be performed. * To be ceaned more frequenty in dusty areas. ** Must be performed to maintain emissions warranty. Periodic Maintenance Chart Operation Service Intervas Air fiter eement ceaning Spark pug : Ceaning & gap setting : Repacement Check and adjust vave cearance Cean inine fue fiter Carburetor ceaning/overhau Contro cabes adjustment Tightening nuts, bots, fastners Cean & adjust front & rear brakes Check front & rear shock absorber Check and adjust steering coumn 300 Recommended Odometer Reading in mies

28 Lubrication Chart Operation Lubricant to be used 300 Recommended Odometer Reading in mies Engine oi repacement SAE 15W50 Every 3000 mies Oi fiter ceaning Fire Proof Sovent Every 3000 mies Repace oi fiter Brake, cutch ever Speedo fex drive, pinion GREASE GREASE Steering races GREASE Stand pin SAE 15W50 Gear shifter assy GREASE Contro cabes SAE 15W50 Whee bearings GREASE Indicates operation to be performed. Brake actuating shaft Front suspension GREASE GREASE Refer Page No

29 Front Whee Remova Put the vehice on stand. Remove nuts securing whee to the axe fange by using box spanner, whie oosening these nuts hod the whee by hand or appy front brake. Take out spring washers. Pu the whee from axe fange studs. Front Whee Instaation Rear Whee Instaation Front Whee Instaation Reverse the above sequence. Tighten the whee nuts securey. Rear Whee Remova The procedure for using the jack is as foows. 1) Loosen the whee nuts (before putting the jack) with the vehice in center stand on position. 2) Put the jack by ocating it on the rear shocker mounting boss & siding it on the ground by right hand, whie pushing the grab up with the eft hand from the rear side of the vehice. Ensure the jack is having a round contact with the shocker mtg boss & is firm on the ground. Check for the gap between front whee & ground. Preferaby front whee shoud not touch the ground. (Avoid using jack on roads having sope in forward direction) 19

30 3) Dismante/Assembe the rear whee. Engage the whee nuts by hand (Do not tighten). 4) Remove the jack. 5) Put the vehice in 1st gear and tighten the whee nuts. Rear Whee Instaation Reverse the above sequence. Tighten the nuts securey. Check for free rotation, brake effectiveness and engine starting. Warning Do not forget to insta the spring washer before Instaing the whee nuts, tighten the whee nuts securey. Whie removing the rear whee protect your hand from the hot siencer. Caution Once the whee repacement is over, confirm the free rotation of whee and brake effectiveness. 20

31 Tire Change Tire Change For repacing a fat tire, unscrew the nuts, which secure the whee to brake drum and side off the whee. Repair the tube or fit on the spare whee. In case of rear whee, use the jack as described in previous page. For removing a tire & tube first defate the tube and unscrew the nuts on the whee so that the two haves of the rim fa apart. (Refer fig.) Do not forget to put spring washers before tightening the nuts at the time of reassemby. Tighten the nuts diagonay and eveny. Stay for hoding the seat upright Stay for hoding the seat upright is boted to seat bracket. This wi hod the seat upright. For this, stay shoud be moved beow the seat. Whie owering the seat, care shoud be taken to remove this stay. Stay for hoding the seat upright 21

32 Recommendations for safe and proper operation of vehice Warning: Do not overoad your scooter. Attach uggage or packages as cose as possibe to the center of your scooter and distribute the oad from side to side as eveny as possibe to keep imbaance to a minimum. Remember that oads tend to oosen with riding. So frequenty check the security of your oad. Do not carry packages that protrude from the uggage rack or which cover any of the signa ights, the headight, or the horn. Do not hang anything from your scooter s handebars, fenders or forks because this wi upset the handing of your scooter and coud prevent you from avoiding an accident. Faiure to heed this warning can ead to an upset with subsequent serious injury or even death. When carrying a passenger, remember that your scooter s handing is degraded, that the brakes are ess efficient, and the center of gravity is higher and further to the rear. This makes it more ikey that the front whee wi come off the ground, especiay during acceeration. Therefore you shoud avoid hard acceeration and hard braking. Many accidents are caused by inexperienced riders carrying passengers. Remember that aowance must be made for the extra weight of the passenger for a driving maneuvers. Avoid abrupt and excessive acceeration. Aways sow down in time and cacuate onger stopping and maneuvering distances. Faiure to heed these instructions may ead to the overturning of the vehice or to other accidents with subsequent serious injuries or even death. Never carry animas or sma chidren on the gove compartment or on the uggage rack. 22

33 Recommendations for safe and proper functioning of vehice Continued use of origina Bajaj repacement parts by an authorized Bajaj Deaer. Before using your scooter check - Fue tank - Gear box/sump oi eve - Tires correcty infated - Lights and turn indicators working propery - Front and rear brakes working propery Ensure tightening of foowing fasteners to specified torques - Cyinder head : Lb-Ft - Hande bar : Lb-Ft - Whee nut : Lb-Ft - Front axe nut : Lb-Ft Carburetor Specifications Make and Type Keihin PB 20 AS/VCS setting from fuy cosed position 2 ¼ ± ½ turns Free pay for Front brake ever : 3-5mm (1/8-1/4 inch) Rear brake peda : 10-15mm (1/16-5/8 inch) Cutch ever : 3-5mm (1/8-1/4 inch) Acceerator grip : 4-5mm (3/16 - inch) 23

34 Service Record1 To maintain your vehice s warranty, reguar inspection and maintenance by your authorized Bajaj Deaer is required. The first service interva shoud be performed between 300 and 500 mies or the first 30 days whichever comes first. See reverse for required service. Owner s Name : Vin # : Date of Sae : Date of Service : Mieage : Service Deaer s Signature :

35 First Service Check and correct tire pressure. Fush and refi engine oi. Check & cean oi strainer. Check & adjust vave cearance. Cean & adjust spark pug gap. Check and tighten nuts for front/rear shock absorber bots, engine foundation bots, hande bar ock bot and front/rear whee nuts. Check & adjust a contro cabes. Carry out ubrication as per ubrication chart. Check front/rear brakes for effective operation. Check a ights, horn and switch operations for satisfactory working. Air fiter eement to be ceaned, if frequenty used in dusty area. Check battery eectroyte eve, top up if necessary & appy petroeum jey on terminas. Test drive the vehice before deivery. Cean the vehice before deivery.

36 Service Record2 To maintain your vehice s warranty, reguar inspection and maintenance by your authorized Bajaj Deaer is required. The second service interva shoud be performed between 1200 and 1500 mies. See reverse for required service. Owner s Name : Vin # : Date of Sae : Date of Service : Mieage : Service Deaer s Signature :

37 Second Service Check and correct tire pressure. Check engine oi eve, top up if necessary. Check & adjust vave cearance. Cean & adjust spark pug gap. Check and tighten nuts for front/rear shock absorber bots, engine foundation bots, hande bar ock bot and front/rear whee nuts. Check & adjust a contro cabes. Carry out ubrication as per ubrication chart. Check front/rear brakes for effective operation. Check a ights, horn and switch operations for satisfactory working. Air fiter eement to be ceaned, if frequenty used in dusty area. Check battery eectroyte eve, top up if necessary & appy petroeum jey on terminas. Test drive the vehice before deivery. Cean the vehice before deivery.

38 Service Record3 To maintain your vehice s warranty, reguar inspection and maintenance by your authorized Bajaj Deaer is required. The third service interva shoud be performed between 2800 and 3100 mies. See reverse for required service. Owner s Name : Vin # : Date of Sae : Date of Service : Mieage : Service Deaer s Signature :

39 Third Service Check and correct tire pressure. Fush and refi engine oi. Check & cean oi strainer & inine fue fiter. Check & adjust vave cearance. Cean & adjust spark pug gap. Cean the air fiter. Cean the carburetor and adjust iding. Check and tighten nuts for front/rear shock absorber bots, engine foundation bots, hande bar ock bot and front/rear whee nuts. Check & adjust a contro cabes. Carry out ubrication as per ubrication chart. Check front/rear brakes for effective operation. Check & adjust steering coumn. Check a ights, horn and switch operations for satisfactory working. Check battery eectroyte eve, top up if necessary & appy petroeum jey on terminas. Test drive the vehice before deivery. Cean the vehice before deivery.

40 Service Record4 To maintain your vehice s warranty, reguar inspection and maintenance by your authorized Bajaj Deaer is required. The fourth service interva shoud be performed between 6000 and 6300 mies. See reverse for required service. Owner s Name : Vin # : Date of Sae : Date of Service : Mieage : Service Deaer s Signature :

41 Fourth Service Check and correct tire pressure. Fush and refi engine oi. Check & cean oi strainer & in-ine fue fiter. Repace if required. Check & adjust vave cearance. Cean & adjust spark pug gap. Repace if required. Cean the air fiter. Cean the carburetor and adjust iding. Check and tighten nuts for front/rear shock absorber bots, engine foundation bots, hande bar ock bot and front/rear whee nuts. Check & adjust a contro cabes. Carry out ubrication as per ubrication chart. Check front/rear brakes for effective operation. Check and adjust steering coumn. Check a ights, horn and switch operations for satisfactory working. Check battery eectroyte eve, top up if necessary & appy petroeum jey on terminas. Test drive the vehice before deivery. Cean the vehice before deivery.

42 Service Record5 To maintain your vehice s warranty, reguar inspection and maintenance by your authorized Bajaj Deaer is required. The fifth service interva shoud be performed between 9000 and 9300 mies. See reverse for required service. Owner s Name : Vin # : Date of Sae : Date of Service : Mieage : Service Deaer s Signature :

43 Fifth Service Check and correct tire pressure. Fush and refi engine oi. Check & cean oi strainer & in-ine fue fiter. Check & adjust vave cearance. Cean & adjust spark pug gap. Cean the air fiter. Cean the carburetor and adjust iding. Check and tighten nuts for front/rear shock absorber bots, engine foundation bots, hande bar ock bot and front/rear whee nuts. Check & adjust a contro cabes. Carry out ubrication as per ubrication chart. Check front/rear brakes for effective operation. Check and adjust steering coumn. Check a ights, horn and switch operations for satisfactory working. Check battery eectroyte eve, top up if necessary & appy petroeum jey on terminas. Test drive the vehice before deivery. Cean the vehice before deivery.

44 Bajaj Auto Ltd. - Emission Contro System Warranty Statement Your Warranty Rights and Obigations The Caifornia Air Resources Board and Bajaj Auto Ltd. (hereinafter Bajaj) are peased to expain the emission contro system warranty on your 2002 and ater motorcyce. In Caifornia new motor vehices must be designed, buit and equipped to meet the State s stringent anti-smog standards. Bajaj must warrant the emission contro system on your motorcyce for the periods of time isted beow provided there has been no abuse, negect or improper maintenance of your motorcyce. Your emission contro system may incude parts such as the carburetor or fue-injection system, the ignition system, cataytic converter and engine computer. Aso incuded may be hoses, bets, connectors and other emissionreated assembies. Where a warrantabe condition exists, Bajaj wi repair your motorcyce at no cost to you, incuding diagnosis, parts and abor. Manufacturer s Warranty Coverage Cass I motorcyce ( cc) for a period of five (5) years or 12,000 kiometers (7,456 mies), whichever first occurs. Cass II motorcyces (170 to 279 cc) for a period of use of five (5) years or 18,000 kiometers (11,185 mies), whichever first occurs. Cass III motorcyces (280 cc and arger) for a period of use of five (5) years or 30,000 kiometers (18,641 mies), whichever first occurs. If an emission-reated part on your motorcyce is defective, the part wi be repaired or repaced by Bajaj. This is your emission contro system Defects Warranty.

45 Owner s Warranty Responsibiities As the motorcyce owner, you are responsibe for the performance of the required maintenance isted in your owner s manua. Bajaj recommends that you retain a receipts covering maintenance on your motorcyce, but Bajaj cannot deny warranty soey for the ack of receipts or for your faiure to ensure the performance of a schedued maintenance. You are responsibe for presenting your motorcyce to a Bajaj deaer as soon as a probem exists. The warranty repairs shoud be competed in a reasonabe amount of time, not to exceed 30 days. As the motorcyce owner, you shoud be aware that Bajaj may deny your warranty coverage if your motorcyce or a part has faied due to abuse, negect, improper maintenance or unapproved modifications. If you have any questions regarding your warranty rights and responsibiities, you shoud contact Bajaj USA, 526 Ecces Avenue, South San Francisco, CA 94080, or the Caifornia Air Resources Board, P.O. Box 8001, 9528 Testar Avenue, EI Monte, CA

46 Bajaj USA - Limited Warranty on Emission Contro System Bajaj USA, 526 Ecces Avenue, South San Francisco, CA (hereinafter Bajaj) warrants that each new 2002 and ater Bajaj motorcyce, that incudes as standard equipment a headight, taiight and stopight, and is street ega: A. is designed, buit and equipped so as to conform at the time of initia retai purchase with a appicabe reguations of the United States Environmenta Protection Agency, and the Caifornia Air Resources Board; and B. is free from defects in materia and workmanship which cause such motorcyce to fai to conform with appicabe reguations of the United States Environmenta Protection Agency or the Caifornia Air Resources Board for a period of use, depending on the engine dispacement, of 12,000 kiometers (7,456 mies), if the motorcyce s engine dispacement is ess than 170 cubic centimeters; of 18,000 kiometers (11,185 mies), if the motorcyce s engine dispacement is equa to or greater than 170 cubic centimeters but ess than 280 cubic centimeters; or of 30,000 kiometers (18,641 mies), if the motorcyce s engine dispacement is 280 cubic centimeters or greater; or 5 (five) years from the date of initia retai deivery, whichever first occurs. I. Coverage: Warranty defects sha be remedied during customary business hours at any authorized Bajaj motorcyce deaer ocated within the United States of America. Any part or parts repaced under this warranty sha become the property of Bajaj.

47 In the State of Caifornia ony, emission reated warranted parts are specificay defined by the state s Emission Warranty Parts List. These warranted parts are: Carburetor and interna parts; Intake manifod; Fue tank; Fue injection system; Spark advance mechanism; Crankcase breather; Air cutoff vaves; Fue tank cap for evaporative emission controed vehices; Oi fier cap; Pressure contro vave; Fue/vapor separator; Canister; Igniters; Breaker governors; Ignition cois; Ignition wires; Ignition points; Condensers, and Spark pugs if faiure occurs prior to the first schedued repacement; and Hoses, Camps, Fittings and tubing used directy in these parts. Since emission reated parts may vary from mode to mode, certain modes may not contain a of these parts and certain modes may contain functionay equivaent parts. In the State of Caifornia ony, Emission Contro System emergency repairs, as provided for in the Caifornia Administrative Code, may be performed by other than an authorized Bajaj deaer. An emergency situation occurs when an authorized Bajaj deaer is not reasonaby avaiabe, a part is not avaiabe within 30 days, or a repair is not compete within 30 days. Any repacement part can be used in an emergency repair. Bajaj wi reimburse the owner for the expenses, incuding diagnosis, not to exceed Bajaj s suggested retai price for a warranted parts repaced and abor charges based on Bajaj s recommended time aowance for the warranty repair and the geographicay appropriate houry abor rate. The owner may be required to keep receipts and faied parts in order to receive compensation.

48 II. Limitations: This Emission Contro System warranty sha not cover any of the foowing: A. Repair or repacement required as a resut of accident, misuse, repairs impropery performed or repacements impropery instaed, use of repacement parts or accessories not conforming to Bajaj specification which adversey affect performance and or use in competitive racing or reated events B. Inspections, repacement of parts and other services and adjustments required for required maintenance. C. Any motorcyce on which the odometer mieage has been changed so that actua mieage cannot be readiy determined. III. Limited Liabiity A. The iabiity of Bajaj under this Emission Contro System Warranty is imited soey to the remedying of defects in materia or workmanship by an authorized Bajaj motorcyce deaer at its pace of business during customary business hours. This warranty does not cover inconvenience or oss of use of the motorcyce or transportation of the motorcyce to or from the Bajaj deaer.

49 Bajaj sha not be iabe for any other expenses, oss or damage, whether direct, incidenta, consequentia or exempary arising in connection with the sae or use of or inabiity to use the Bajaj motorcyce for any purpose. Some states do not aow the excusion or imitation of any incidenta or consequentia damages, so the above imitations may not appy to you. B. No express emission contro system warranty is given by Bajaj except as specificay set forth herein. Any emission contro system warranty impied by aw, incuding any warranty of merchantabiity or fitness for a particuar purpose, is imited to the express emission contro system warranty terms stated in this warranty. The foregoing statements of warranty are excusive and in ieu of a other remedies. Some states do not aow imitations on how ong an impied warranty asts so the above imitations may not appy to you. C. No deaer is authorized to modify this Bajaj Limited Emission Contro System Warranty. IV. Lega Rights: This warranty gives you specific ega rights, and you may aso have other rights which vary from state to state. V. This warranty is in addition to the Bajaj Limited Motorcyce Warranty.

50 VI. Additiona Information: Any repacement part that is equivaent in performance and durabiity may be used in the performance of any maintenance or repairs. However, Bajaj is not iabe for these parts. The owner is responsibe for the performance of a required maintenance. Such maintenance may be performed at a service estabishment or by any individua. The warranty period begins on the date the motorcyce is deivered to an utimate purchaser. Manufacturer: Bajaj Auto Ltd., Akurdi, Pune, India Importer: Bajaj USA, 526 Ecces Avenue, South San Francisco, CA 94080

51 Owner s Manua Notice - Reporting of Safety Defects If you beieve that your vehice has a defect which coud cause a crash or coud cause injury or death, you shoud immediatey inform the Nationa Highway Traffic Safety Administration (NHTSA) in addition to notifying (manufacturer). If NHTSA receives simiar compaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehices, it may order a reca and remedy campaign. However, NHTSA cannot become invoved in individua probems between you, your deaer, or (manufacturer). To contact NHTSA, you may either ca the Auto Safety Hotine to-free at (or in Washington, D.C. area) or write to : NHTSA, U.S. Department of Transportation, Washington, D.C , You can aso obtain other information about motor vehice safety from the Hotine.

52 Noise Emission Warranty: Bajaj Auto Ltd. warrants that this exhaust system, at the time of sae, meets a appicabe U.S. EPA Federa noise standards. This warranty extends to the first person who buys this exhaust system for purposes other than resae, and to a subsequent buyers. Warranty caims shoud be directed to: Bajaj USA, 526 Ecces Avenue, South San Francisco, CA Tampering Warning: Tampering with Noise Contro System Prohibited. Federa aw prohibits the foowing acts or causing thereof: (1) The remova or rendering inoperative by any person other than for purposes of maintenance, repair, or repacement, of any device or eement of design incorporated into any new vehice for the purpose of noise contro prior to its sae or deivery to the utimate purchaser or whie it is in use, or (2) The use of the vehice after such device or eement of design has been removed or rendered inoperative by any person.

53 Among those acts presumed to constitute tampering are the acts isted beow: (1) Remova of, or puncturing the muffer, baffes, header pipes or any other component which conducts exhaust gases. (2) Remova or puncturing of any part of the intake system. (3) Lack of proper maintenance. (4) Repacing any moving part of the vehice, or parts of the exhaust or intake system, with parts other than those specified by the manufacturer. Warning Statement: This product shoud be checked for repair or repacement if the motorcyce noise has increased significanty through use. Otherwise, the owner may become subject to penaties under state or oca ordinances.

54 Warranty Statement The foowing warranty appies to Bajaj scooters distributed by Bajaj USA. The warranty is the ony warranty on these products, other than the emission contro system, and noise emission contro system set out esewhere. No express warranty is given by Bajaj USA except as specificay set forth herein. Any warranty impied by aw, incuding any warranty of merchantabiity or of fitness for a particuar purpose, or for any purpose, is imited to the express terms stated in this warranty. The statements of warranty herein are excusive and in ieu of a other remedies. Some states do not aow imitations on how ong an impied warranty asts so the above imitations may not appy to you. Every possibe care and precaution has been taken to ensure quaity in respect of materia and workmanship in the vehices manufactured by Bajaj Auto Ltd. Bajaj USA wi repace or repair, at their authorized workshop/s, free of charge, within a period of 12 months from the date of sae of the vehice to the first owner or unti the vehice has been driven for 6000 mies, which ever sha occur first, such part or parts thereof as may be found, on examination, to have manufacturing defect. Bajaj USA undertake no iabiity in the matter of consequentia oss or damage caused due to the faiure of the parts. Deay, if any, at the repairing workshop in carrying out repair to vehice sha not be grounds for extending the warranty period, nor sha it give any right to the customer for caiming any compensation or damages. Bajaj USA reserves the right to either repair or repace the defective parts. Where a defective part can be repaced by part/s or aternative brand/s, which are normay used by Bajaj

55 Auto Ltd. in the course of manufacture, Bajaj USA reserves the right to carry out the repacement by a part or parts of any such aternative brand/s. This warranty and any caim arising there from are subject to United States of America jurisdiction ony. No caim for exchange or repair wi be considered uness the customer: (a) Ensures that immediatey upon discovery of the defect, he/she approaches any nearest Authorized Bajaj Vehice deaer. (b) Produce documentation to demonstrate ownership and date of purchase. No caim presented directy to Bajaj USA by the purchaser of the Product wi be considered. A warranty caims must be processed through the oca Bajaj deaer. Bajaj USA accepts no responsibiity for any product or part thereof returned to Bajaj USA headquarters. There is no warranty of any kind on the foowing: (1) Norma maintenance operations such as brake and cutch adjustments, ceaning of fue system, engine tune-up or such other adjustments. (2) Repacement of eectrica items ike bubs, fuses, reays, or batteries. Repair or repacement of rubber items ike tires, inner tubes, handgrips, footpeg covers, and other rubber or eastomeric items. (3) Parts of the vehice that have been subject to misuse, accident, negigent treatment OR which have

56 been used in conjunction with parts and equipment not manufactured or recommended for use by Bajaj USA. (4) Parts of the vehice that been atered and modified or repaced in an unauthorized manner. (5) Vehices which are not being serviced by Authorized Bajaj vehice deaers as per the service schedue described in the owner s manua or which have not been operated or maintained in accordance with the instructions mentioned in the owner s manua. (6) Vehices used for any competition. Bajaj USA reserves the right to make any changes in design or to add any improvements on the vehice at any time without incurring any obigation to insta the same on vehices previousy suppied and sod. Aso, the conditions of this warranty are subject to ateration without any notice. This warranty is the entire written warranty given by Bajaj USA for Bajaj scooters and no other person, incuding the deaer or his/her agent or empoyee is authorized to extend or enarge this warranty. This warranty is given in ieu of and excudes every condition or warranty whether statutory or otherwise not herein expressy set out.

57 TM